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Sulfuric Acid Manufacture: Analysis, Control and Optimization 2nd edition [Kõva köide]

, (University of Utah, UT, USA), (Emeritus Prof. William Davenport, Department of Materials Science and Engineering, University of Arizona, Tuscon, AZ, USA)
  • Formaat: Hardback, 608 pages, kõrgus x laius: 229x152 mm, kaal: 960 g, 90 illustrations; Illustrations, unspecified
  • Ilmumisaeg: 29-May-2013
  • Kirjastus: Elsevier / The Lancet
  • ISBN-10: 0080982204
  • ISBN-13: 9780080982205
Teised raamatud teemal:
Sulfuric Acid Manufacture: Analysis, Control and Optimization 2nd editionSuurem pilt
  • Formaat: Hardback, 608 pages, kõrgus x laius: 229x152 mm, kaal: 960 g, 90 illustrations; Illustrations, unspecified
  • Ilmumisaeg: 29-May-2013
  • Kirjastus: Elsevier / The Lancet
  • ISBN-10: 0080982204
  • ISBN-13: 9780080982205
Teised raamatud teemal:
Püsilink: https://www.kriso.ee/db/9780080982205.html

By some measure the most widely produced chemical in the world today, sulfuric acid has an extraordinary range of modern uses, including phosphate fertilizer production, explosives, glue, wood preservative and lead-acid batteries. An exceptionally corrosive and dangerous acid, production of sulfuric acid requires stringent adherence to environmental regulatory guidance within cost-efficient standards of production.

This work provides an experience-based review of how sulfuric acid plants work, how they should be designed and how they should be operated for maximum sulfur capture and minimum environmental impact. Using a combination of practical experience and deep physical analysis, Davenport and King review sulfur manufacturing in the contemporary world where regulatory guidance is becoming ever tighter (and where new processes are being required to meet them), and where water consumption and energy considerations are being brought to bear on sulfuric acid plant operations. This 2e will examine in particular newly developed acid-making processes and new methods of minimizing unwanted sulfur emissions.

The target readers are recently graduated science and engineering students who are entering the chemical industry and experienced professionals within chemical plant design companies, chemical plant production companies, sulfuric acid recycling companies and sulfuric acid users. They will use the book to design, control, optimize and operate sulfuric acid plants around the world.

Unique mathematical analysis of sulfuric acid manufacturing processes, providing a sound basis for optimizing sulfuric acid manufacturing processes.

Analysis of recently developed sulfuric acid manufacturing techniques suggests advantages and disadvantages of the new processes from the energy and environmental points of view.

Analysis of tail gas sulfur capture processes indicates the best way to combine sulfuric acid making and tailgas sulfur-capture processes from the energy and environmental points of view.

Draws on industrial connections of the authors through years of hands-on experience in sulfuric acid manufacture.

Arvustused

"The 2006 first edition has been updated with seven new chapters, and one additional author, MoatsThey consider such topics as metallurgical offgas cooling and cleaning, the catalytic oxidation of S2 to S3, the second catalyst bed heatup path, the three catalyst bed acid plant, acid temperature and control and heat recovery, wet sulfuric acid process fundamentals, and the cost of sulfuric acid production." --Reference & Research Book News, December 2013

Muu info

This book describes sulfuric acid manufacture, analyzes it mathematically; and shows how it may be optimized
Preface xv
1 Overview 1(10)
1.1 Catalytic oxidation of SO2 to SO3
1(2)
1.2 H2SO4 production
3(1)
1.3 Industrial flowsheet
4(1)
1.4 Sulfur burning
4(2)
1.5 Metallurgical offgas
6(1)
1.6 Spent acid regeneration
6(1)
1.7 Sulfuric acid product
7(1)
1.8 Recent developments
7(1)
1.9 Alternative processes
7(1)
1.10 Summary
8(3)
2 Production and consumption 11(8)
2.1 Uses
13(1)
2.2 Acid plant locations
14(1)
2.3 Price
14(2)
2.4 Summary
16(3)
3 Sulfur burning 19(12)
3.1 Objectives
20(1)
3.2 Sulfur
20(1)
3.3 Molten sulfur delivery
21(1)
3.4 Sulfur atomizers and sulfur burning furnaces
22(1)
3.5 Product gas
23(5)
3.6 Heat recovery boiler
28(1)
3.7 Summary
29(2)
4 Metallurgical offgas cooling and cleaning 31(16)
4.1 Initial and final SO2 concentrations
31(2)
4.2 Initial and final dust concentrations
33(1)
4.3 Offgas cooling and heat recovery
34(1)
4.4 Electrostatic collection of dust
35(2)
4.5 Water scrubbing
37(6)
4.6 H20(g) removal from scrubber exit gas
43(1)
4.7 Summary
44(3)
5 Regeneration of spent sulfuric acid 47(12)
5.1 Spent acid compositions
47(4)
5.2 Spent acid handling
51(1)
5.3 Decomposition
51(1)
5.4 Decomposition furnace product
52(1)
5.5 Optimum decomposition furnace operating conditions
53(1)
5.6 Preparation of offgas for SO2 oxidation and H2SO4 making
54(2)
5.7 Summary
56(3)
6 Dehydrating air and gases with strong sulfuric acid 59(14)
6.1
Chapter objectives
59(2)
6.2 Dehydration with strong sulfuric acid
61(3)
6.3 Dehydration reaction mechanism
64(1)
6.4 Residence times
65(5)
6.5 Recent advances
70(1)
6.6 Summary
70(3)
7 Catalytic oxidation of SO2 to SO3 73(18)
7.1 Objectives
73(1)
7.2 industrial SO2 oxidation
73(2)
7.3 Catalyst necessity
75(9)
7.4 SO2 oxidation "heatup" path
84(1)
7.5 Industrial multicatalyst bed SO2 oxidation
84(3)
7.6 Industrial operation
87(2)
7.7 Recent advances
89(1)
7.8 Summary
89(2)
8 SO2 oxidation catalyst and catalyst beds 91(12)
8.1 Catalytic reactions
91(4)
8.2 Maximum and minimum catalyst operating temperatures
95(1)
8.3 Composition and manufacture
95(1)
8.4 Choice of size and shape
96(1)
8.5 Catalyst bed thickness and diameter
97(1)
8.6 Gas residence times
98(1)
8.7 Catalyst bed temperatures
99(1)
8.8 Catalyst bed maintenance
100(1)
8.9 Summary
100(3)
9 Production of H2SO4(e) from S03(g) 103(22)
9.1 Objectives
103(1)
9.2 Sulfuric acid rather than water
104(1)
9.3 Absorption reaction mechanism
105(2)
9.4 Industrial H2SO4 making
107(8)
9.5 Choice of input and output acid compositions
115(1)
9.6 Acid temperature
116(1)
9.7 Gas temperatures
116(1)
9.8 Operation and control
116(2)
9.9 Double contact H2SO4 making
118(2)
9.10 Intermediate versus final H2SO4 making
120(1)
9.11 Summary
120(3)
Break
123(2)
10 Oxidation of SO2 to S03-Equilibrium curves 125(10)
10.1 Catalytic oxidation
125(2)
10.2 Equilibrium equation
127(1)
10.3 KE as a function of temperature
128(1)
10.4 KE in terms of % SO2 oxidized
129(1)
10.5 Equilibrium % SO2 oxidized as a function of temperature
129(3)
10.6 Discussion
132(1)
10.7 Summary
132(1)
10.8 Problems
132(3)
11 SO2 oxidation heatup paths 135(16)
11.1 Heatup paths
135(1)
11.2 Objectives
135(1)
11.3 Preparing a heatup path-The first point
136(1)
11.4 Assumptions
136(1)
11.5 A specific example
136(1)
11.6 Calculation strategy
137(1)
11.7 Input SO2, O2, and N2 quantities
138(1)
11.8 Sulfur, oxygen, and nitrogen molar balances
139(1)
11.9 Enthalpy balance
140(2)
11.10 Calculating level L quantities
142(1)
11.11 Matrix calculation
143(1)
11.12 Preparing a heatup path
143(2)
11.13 Feed gas SO2 strength effect
145(2)
11.14 Feed gas temperature effect
147(1)
11.15 Significance of heatup path position and slope
148(1)
11.16 Summary
149(1)
11.17 Problems
150(1)
12 Maximum SO2 oxidation: Heatup path-equilibrium curve intercepts 151(10)
12.1 Initial specifications
151(1)
12.2 % SO2 oxidized-temperature points near an intercept
151(2)
12.3 Discussion
153(1)
12.4 Effect of feed gas temperature on intercept
153(1)
12.5 Inadequate % SO2 oxidized in first catalyst bed
154(1)
12.6 Effect of feed gas SO2 strength on intercept
154(1)
12.7 Minor influence-Equilibrium gas pressure
154(1)
12.8 Minor influence-O2 strength in feed gas
155(1)
12.9 Minor influence-CO2 in feed gas
155(2)
12.10 Catalyst degradation, SO2 strength, and feed gas temperature
157(1)
12.11 Maximum feed gas SO2 strength
158(1)
12.12 Exit gas composition intercept gas composition
159(1)
12.13 Summary
160(1)
12.14 Problems
160(1)
13 Cooling first catalyst bed exit gas 161(6)
13.1 First catalyst bed summary
161(1)
13.2 Cooldown path
161(3)
13.3 Gas composition below equilibrium curve
164(1)
13.4 Summary
164(1)
13.5 Problem
164(3)
14 Second catalyst bed heatup path 167(10)
14.1 Objectives
167(1)
14.2 % SO2 oxidized redefined
167(1)
14.3 Second catalyst bed heatup path
168(2)
14.4 A specific heatup path question
170(1)
14.5 Second catalyst bed input gas quantities
170(1)
14.6 S, 0, and N molar balances
171(1)
14.7 Enthalpy balance
171(1)
14.8 Calculating 760 K (level L) quantities
172(1)
14.9 Matrix calculation and result
173(1)
14.10 Preparing a heatup path
173(1)
14.11 Discussion
173(2)
14.12 Summary
175(1)
14.13 Problem
176(1)
15 Maximum SO2 oxidation in a second catalyst bed 177(6)
15.1 Second catalyst bed equilibrium curve equation
177(1)
15.2 Second catalyst bed intercept calculation
178(2)
15.3 Two bed SO2 oxidation efficiency
180(1)
15.4 Summary
181(1)
15.5 Problems
181(2)
16 Third catalyst bed SO2 oxidation 183(6)
16.1 2-3 Cooldown path
183(1)
16.2 Heatup path
184(3)
16.3 Heatup path-equilibrium curve intercept
187(1)
16.4 Graphical representation
187(1)
16.5 Summary
187(1)
16.6 Problems
187(2)
17 SO3 and CO2 in feed gas 189(10)
17.1 SO3
189(4)
17.2 SO3 effects
193(1)
17.3 CO2
193(4)
17.4 CO2 effects
197(1)
17.5 Summary
197(1)
17.6 Problems
198(1)
18 Three catalyst bed acid plant 199(12)
18.1 Calculation specifications
199(1)
18.2 Example calculation
199(1)
18.3 Calculation results
199(2)
18.4 Three catalyst bed graphs
201(1)
18.5 Minor effect-SO3 in feed gas
202(1)
18.6 Minor effect-CO2 in feed gas
202(2)
18.7 Minor effect-Bed pressure
204(1)
18.8 Minor effect-S02 strength in feed gas
204(2)
18.9 Minor effect-O2 strength in feed gas
206(1)
18.10 Summary of minor effects
206(1)
18.11 Major effect-Catalyst bed input gas temperatures
207(1)
18.12 Discussion of book's assumptions
208(1)
18.13 Summary
209(2)
19 After-H2SO4-making SO2 oxidation 211(18)
19.1 Double contact advantage
211(2)
19.2 Objectives
213(1)
19.3 After-H2SO4-making calculations
213(2)
19.4 Equilibrium curve calculation
215(1)
19.5 Heatup path calculation
216(1)
19.6 Heatup path-equilibrium curve intercept calculation
216(1)
19.7 Overall SO2 oxidation efficiency
217(4)
19.8 Double/single contact comparison
221(1)
19.9 Summary
222(5)
19.10 Problems
227(2)
20 Optimum double contact acidmaking 229(6)
20.1 Total % SO2 oxidized after all catalyst beds
230(1)
20.2 Four catalyst beds
230(1)
20.3 Improved efficiency with five catalyst beds
231(1)
20.4 Input gas temperature effect
231(1)
20.5 Best bed for Cs catalyst
232(1)
20.6 Triple contact acid plant
233(1)
20.7 Summary
234(1)
21 Enthalpies and enthalpy transfers 235(8)
21.1 Input and output gas enthalpies
235(3)
21.2 H2SO4 making input gas enthalpy
238(1)
21.3 Heat transfers
239(1)
21.4 Heat transfer rate
240(1)
21.5 Summary
241(1)
21.6 Problems
241(2)
22 Control of gas temperature by bypassing 243(8)
22.1 Bypassing principle
243(1)
22.2 Objective
243(2)
22.3 Gas to economizer heat transfer
245(1)
22.4 Heat transfer requirement for 480 K economizer output gas
245(1)
22.5 Changing heat transfer by bypassing
246(1)
22.6 460 K Economizer output gas
247(1)
22.7 Bypassing for 460, 470, and 480 K economizer output gas
247(1)
22.8 Bypassing for 470 K economizer output gas while input gas temperature is varying
248(1)
22.9 Industrial bypassing
249(1)
22.10 Summary
249(1)
22.11 Problems
250(1)
23 H2SO4 making 251(16)
23.1 Objectives
252(1)
23.2 Mass balances
252(1)
23.3 SO3 input mass
253(1)
23.4 H20(g) input from moist acid plant input gas
253(2)
23.5 Water for product acid
255(1)
23.6 Calculation of mass water in and mass acid out
255(3)
23.7 Interpretations
258(3)
23.8 Summary
261(1)
23.9 Problem
262(5)
24 Acid temperature control and heat recovery 267(16)
24.1 Objectives
267(1)
24.2 Calculation of output acid temperature
267(5)
24.3 Effect of input acid temperature
272(1)
24.4 Effect of input gas temperature
273(1)
24.5 Effect of input gas SO3 concentration on output acid temperature
273(1)
24.6 Adjusting output acid temperature
274(1)
24.7 Acid cooling
275(1)
24.8 Target acid temperatures
276(1)
24.9 Recovery of acid heat as steam
276(2)
24.10 Steam production principles
278(1)
24.11 Double-packed bed absorption tower
278(1)
24.12 Steam injection
279(1)
24.13 Sensible heat recovery efficiency
279(1)
24.14 Materials of construction
280(1)
24.15 Summary
280(1)
24.16 Problems
280(3)
25 Making sulfuric acid from wet feed gas 283(12)
25.1
Chapter objectives
283(1)
25.2 WSA feed Gas
284(1)
25.3 WSA flowsheet
285(2)
25.4 Catalyst bed reactions
287(1)
25.5 Preparing the oxidized gas for 1-12SO4(e) condensation
288(1)
25.6 H2SO4(e) condenser
289(2)
25.7 Product acid composition
291(1)
25.8 Comparison with conventional acidmaking
291(1)
25.9 Appraisal
292(1)
25.10 Alternatives
292(1)
25.11 Summary
293(2)
26 Wet sulfuric acid process fundamentals 295(18)
26.1 Wet gas sulfuric acid process SO2 oxidation
295(4)
26.2 Injection of nanoparticles into cooled process gas
299(3)
26.3 Sulfuric acid condensation
302(3)
26.4 Condenser temperature choices
305(2)
26.5 Condenser acid composition up the glass tube
307(1)
26.6 Condenser re-evaporation of H20(e)
307(1)
26.7 Condenser acid production rate
308(1)
26.8 Condenser appraisal
309(1)
26.9 Summary
310(3)
27 SO3 gas recycle for high SO2 concentration gas treatment 313(12)
27.1 Objectives
313(1)
27.2 Calculations
313(1)
27.3 Effect of recycle extent
314(1)
27.4 Effect of recycle gas temperature on recycle requirement
315(2)
27.5 Effect of gas recycle on first catalyst SO2 oxidation efficiency
317(1)
27.6 Effect of first catalyst exit gas recycle on overall acid plant performance
318(1)
27.7 Recycle equipment requirements
319(1)
27.8 Appraisal
319(1)
27.9 Industrial SO3 gas recycle
319(2)
27.10 Alternatives to gas recycle
321(2)
27.11 Summary
323(2)
28 Sulfur from tail gas removal processes 325(16)
28.1 Objectives
325(1)
28.2 Environmental standards
325(1)
28.3 Acid plant tail gas characteristics
326(2)
28.4 Industrial acid plant tail gas treatment methods
328(9)
28.5 Technology selection
337(1)
28.6 Capital and operating costs
338(1)
28.7 Summary
338(3)
29 Minimizing sulfur emissions 341(8)
29.1 Industrial catalytic SO2 + 0.502 -> S03 oxidation
341(2)
29.2 Methods to lower sulfur emissions
343(4)
29.3 Summary
347(2)
30 Materials of construction 349(8)
30.1
Chapter objectives
349(1)
30.2 Corrosion rate factors for sulfuric acid plant equipment
349(2)
30.3 Sulfuric acid plant materials of construction
351(5)
30.4 Summary
356(1)
31 Costs of sulfuric acid production 357(6)
31.1 Investment costs
357(3)
31.2 Production costs
360(2)
31.3 Summary
362(1)
Appendix A Sulfuric acid properties 363(6)
Appendix B Derivation of equilibrium equation (10.12) 369(10)
Appendix C Free energy equations for equilibrium curve calculations 379(4)
Appendix D Preparation of Fig. 10.2's equilibrium curve 383(4)
Appendix E Proof that volume % = mol % (for ideal gases) 387(2)
Appendix F Effect of CO2 and Ar on equilibrium equations (none) 389(4)
Appendix G Enthalpy equations for heatup path calculations 393(6)
Appendix H Matrix solving using Tables 11.2 and 14.2 as examples 399(2)
Appendix I Enthalpy equations in heatup path matrix cells 401(4)
Appendix J Heatup path-equilibrium curve: Intercept calculations 405(8)
Appendix K Second catalyst bed heatup path calculations 413(4)
Appendix L Equilibrium equation for multicatalyst bed SO2 oxidation 417(4)
Appendix M Second catalyst bed intercept calculations 421(6)
Appendix N Third catalyst bed heatup path worksheet 427(2)
Appendix O Third catalyst bed intercept worksheet 429(2)
Appendix P Effect of SO3 in Fig. 10.1's feed gas on equilibrium equations 431(8)
Appendix Q SO3-in-feed-gas intercept worksheet 439(2)
Appendix R CO2- and SO3-in-feed-gas intercept worksheet 441(2)
Appendix S Three-catalyst-bed "converter" calculations 443(8)
Appendix T Worksheet for calculating after-intermediate-H2SO4-making heatup path-equilibrium curve intercepts 451(2)
Appendix U After-H2SO4-making SO2 oxidation with SO3 and CO2 in input gas 453(6)
Appendix V Moist air in H2SO4 making calculations 459(2)
Appendix W Calculation of H2SO4 making tower mass flows 461(4)
Appendix X Equilibrium equations for SO2, 02, H20(g), N2 feed gas 465(10)
Appendix Y Cooled first catalyst bed exit gas recycle calculations 475(6)
Answers to numerical problems 481(12)
Index 493
Professor William George Davenport is a graduate of the University of British Columbia and the Royal School of Mines, London. Prior to his academic career he worked with the Linde Division of Union Carbide in Tonawanda, New York. He spent a combined 43 years of teaching at McGill University and the University of Arizona.

His Union Carbide days are recounted in the book Iron Blast Furnace, Analysis, Control and Optimization (English, Chinese, Japanese, Russian and Spanish editions).

During the early years of his academic career he spent his summers working in many of Noranda Mines Companys metallurgical plants, which led quickly to the book Extractive Metallurgy of Copper. This book has gone into five English language editions (with several printings) and Chinese, Farsi and Spanish language editions.

He also had the good fortune to work in Phelps Dodges Playas flash smelter soon after coming to the University of Arizona. This experience contributed to the book Flash Smelting, with two English language editions and a Russian language edition and eventually to the book Sulfuric Acid Manufacture (2006), 2nd edition 2013.

In 2013 co-authored Extractive Metallurgy of Nickel, Cobalt and Platinum Group Metals, which took him to all the continents except Antarctica.

He and four co-authors are just finishing up the book Rare Earths: Science, Technology, Production and Use, which has taken him around the United States, Canada and France, visiting rare earth mines, smelters, manufacturing plants, laboratories and recycling facilities.

Professor Davenports teaching has centered on ferrous and non-ferrous extractive metallurgy. He has visited (and continues to visit) about 10 metallurgical plants per year around the world to determine the relationships between theory and industrial practice. He has also taught plant design and economics throughout his career and has found this aspect of his work particularly rewarding. The delight of his life at the university has, however, always been academic advising of students on a one-on-one basis.

Professor Davenport is a Fellow (and life member) of the Canadian Institute of Mining, Metallurgy and Petroleum and a twenty-five year member of the (U.S.) Society of Mining, Metallurgy and Exploration. He is recipient of the CIM Alcan Award, the TMS Extractive Metallurgy Lecture Award, the AusIMM Sir George Fisher Award, the AIME Mineral Industry Education Award, the American Mining Hall of Fame Medal of Merit and the SME Milton E. Wadsworth award. In September 2014 he will be honored by the Conference of Metallurgists Bill Davenport Honorary Symposium in Vancouver, British Columbia (his home town).